TOYOTA SUPRA 1995 Service Repair Manual

STARTER
COMPONENTS FOR REMOVAL AND
INSTALLATION
± STARTING SYSTEMSTARTERST±3

STARTER REMOVAL
Installation is in the reverse order of removal.
REMOVE STARTER
(a) Remove the rubber cap and nut, and disconnect the starter
wire.
(b) Disconnect the starter connector.
(c) Remove the 2 bolts and starter.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY
ST±4± STARTING SYSTEMSTARTER

STARTER DISASSEMBLY
Assembly is in the reverse order of disassembly.
ASSEMBLY HINT: Use high±temperature grease to lubricate
the bearings, gears return spring and steel ball when assem-
bling the starter.
1. REMOVE DUST PROTECTORS
Remove the 2 dust protectors.
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 7.9 NVm (81 kgfVcm, 70 in.Vlbf)
(b) Remove the 2 through bolts.
Torque: 5.9 NVm (60 kgfVcm, 52 in.Vlbf)
(c) Pull out the field frame together with the armature.
ASSEMBLY HINT: Align the protrusion of the field frame with
the groove of the magnetic switch.
(d) Remove the O±ring from the field frame.
ASSEMBLY HINT: Use a new O±ring.
3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY
AND GEAR
(a) Remove the 2 bolts.
Torque: 5.9 NVm (60 kgfVcm, 52 in.Vlbf)
± STARTING SYSTEMSTARTERST±5

(b) Remove these parts from the magnetic switch:
(1) Starter housing
(2) Return spring
(3) Idler gear
(4) Bearing
(5) Clutch assembly
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
5. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, 2 O±rings and end cover from the field
frame.
ASSEMBLY HINT: Use 2 new O±rings.
Torque: 1.5 NVm (15 kgfVcm, 13 in.Vlbf)
(b) Remove the O±ring from the field frame.
ASSEMBLY HINT: Use a new O±ring.
(c) Using a screwdriver, hold the spring back and disconnect the
brush from the brush holder. Disconnect the 4 brushes, and
remove the brush holder.
ASSEMBLY NOTICE: Check that the positive (+) lead wires are
not grounded.
6. REMOVE ARMATURE FROM FIELD FRAME
STARTER INSPECTION AND REPAIR
Armature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between
the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature. ST±6
± STARTING SYSTEMSTARTER

2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is continuity, replace the armature.
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACE
If the surface is dirty or burnt, correct it with sandpaper
(No.400) or on a lathe.
2. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V±blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout:
0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a
lathe.
3. INSPECT COMMUTATOR DIAMETER
Using a vernier caliper, measure the commutator diameter.
Standard diameter:
30.0 mm (1.181 in.)
Minimum diameter:
29.0 mm (1.412 in.)
If the diameter is less than minimum, replace the armature.
4. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth:
0.6 mm (0.024 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.
± STARTING SYSTEMSTARTERST±7

Field Frame (Field Coil)
1. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between
the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
2. INSPECT FIELD COIL FOR GROUND
Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, replace the field frame.
Brushes
INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length:
15.5 mm (0.610 in.)
Minimum length:
10.0 mm (0.394 in.)
If the length is less than minimum, replace the brush holder
and field frame.
Brush Springs
INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Spring installed load:
18±24 N (1.79±2.41 kgf, 3.9±5.3 lbf)
If the installed load is not within specification, replace the
brush springs. ST±8
± STARTING SYSTEMSTARTER

Brush Holder
INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
If there is continuity, repair or replace the brush holder.
Clutch and Gears
1. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.
2. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear counterclockwise, and check that it
turns freely. Try to rotate the pinion gear clock±wise and
check that it locks.
If necessary, replace the clutch assembly.
Bearings
1. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
2. IF NECESSARY, REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
± STARTING SYSTEMSTARTERST±9

(b) Using a press, press in a new front bearing.
3. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
4. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using SST and a press, press in a new bearing.
NOTICE: Be careful of the bearing installation direction.
SST 09820±00030
Magnetic Switch
1. DO PULL±IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between
terminals 50 and C.
If there is no continuity, replace the magnetic switch. ST±10
± STARTING SYSTEMSTARTER

2. DO HOLD±IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between
terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
STARTER PERFORMANCE TEST
NOTICE: These tests must be performed with in 3 to 5 seconds
to avoid burning out the coil.
1. DO PULL±IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the pinion gear moves outward.
If the pinion gear does not move, replace the magnetic
switch.
2. DO HOLD±IN TEST
While connected as above with the pinion gear out, discon-
nect the negative (±) lead from terminal C.
Check that the pinion gear remains out.
If the pinion gear returns inward, replace the magnetic switch.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (±) lead from the starter body. Check
that the pinion gear returns inward.
If the pinion gear does not return, replace the magnetic
switch.
4. DO NO±LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with the
pinion gear moving out. Check that the ammeter shows the
specified current.
Specified current:
90 A or less at 11.5 V
± STARTING SYSTEMSTARTERST±11

STARTER RELAY
STARTER RELAY INSPECTION
1. REMOVE STARTER RELAY (ºSTº)
LOCATION: In the engine compartment relay box.
Remove the relay box cover and starter relay.
2. INSPECT STARTER RELAY
A. Inspect relay continuity
(a) Using an ohmmeter, check that there is continuity between
terminals 1 and 2.
(b) Check that there is no continuity between terminals 3 and 5.
If continuity is not as specified, replace the relay.
B. Inspect relay operation
(a) Apply battery voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuity between
terminals 2 and 5.
If operation is not as specified, replace the relay.
3. REINSTALL STARTER RELAY ST±12
± STARTING SYSTEMSTARTER RELAY